Rosemount X-STREAM X1-Orig. Issue User manual

Gas Analyzer Series

Instruction Manual

www.EmersonProcess.com

Instruction Manual

HASAxE-IM-HS

07/2006

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management (Rosemount Analytical) designs, manufactures and tests

its products to meet many national and international standards. Because these

instruments are sophisticated technical products, you MUST properly install, use, and

maintain them to ensure they continue to operate within their normal specifications. The

following instructions MUST be adhered to and integrated into your safety program when

installing, using and maintaining Emerson Process Management (Rosemount Analytical)

products. Failure to follow the proper instructions may cause any one of the following

situations to occur: Loss of life; personal injury; property damage; damage to this

instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Emerson Process

Management (Rosemount Analytical) representative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the

product.

• Inform and educate your personnel in the proper installation, operation, and

maintenance of the product.

• Install your equipment as specified in the Installation Instructions of the

appropriate Instruction Manual and per applicable local and national codes.

Connect all products to the proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update,

program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement

parts specified by Emerson Process Management (Rosemount Analytical).

Unauthorized parts and procedures can affect the product’s performance, place the

safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike

substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place,

except when maintenance is being performed by qualified persons, to prevent

electrical shock and personal injury.

The information contained in this document is subject to change without notice.

Emerson Process Management GmbH & Co. OHG

Industriestrasse 1

D-63594 Hasselroth

Germany

T +49 (0) 6055 884-0

F +49 (0) 6055 884-209

Internet: www.EmersonProcess.com

Edition 2006-07

Instruction Manual

HASAxE-IM-HS

04/2006

X-STREAM

Emerson Process Management GmbH & Co. OHG S-1

Safety Instructions

This instruction manual provides information about X-STREAM series gas analyzers

concerning subassemblies, functions, procedures, installation, operation and maintenance.

This instruction manual covers several X-STREAM series analyzer variations and therefore

may describe configurations and/or options not part of your specific analyzer.

Installation and operation of instruments intended to be installed and operated in hazardous

areas is not covered by this instruction manual, but part of the specific instruction manual

shipped together with such analyzers because of the special requirements for working in

hazardous environments!

PREAMBLE

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout

this publication.

DEFINITIONS

Highlights an operation or maintenance procedure, practice, condition, state-

ment, etc.

If not strictly observed, could result in injury, death, or long-term health

hazards of personnel.

NOTE

Highlights an essential operating procedure, condition or statement.

Highlights an operation or maintenance procedure, practice, condition, state-

ment, etc.

If not strictly observed, could result in damage to or destruction of equipment,

or loss of effectiveness.

X-STREAM

Instruction Manual

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04/2006

Emerson Process Management GmbH & Co. OHGS-2

IMPORTANT

Safety Instructions

Wiring and Installation of this Apparatus

The following safety instructions apply specifically to all EU member states. They should be strictly

adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also

comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where

provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The

integrity of all earth terminals must be maintained at all times.

3. To ensure safe operation of this equipment, connection to the mains supply should only be

made through a circuit breaker which will disconnect all circuits carrying conductors during a

fault situation. The circuit breaker may also include a mechanically operated isolating switch.

Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring

must conform with any local standards.

4. Where equipment or covers are marked with the symbol to the right, hazardous

voltages are likely to be present beneath. These covers should only be removed

when power is removed from the equipment — and then by trained service

personnel only.

5. Where equipment or covers are marked with the symbol to the right, there is a

danger from hot surfaces beneath. These covers should only be removed by

trained service personnel when power is removed from the equipment. Certain

surfaces may remain hot to the touch.

6. Where equipment or covers are marked with the symbol to the right, refer to the

Instruction Manual for instructions.

7. Further graphical symbols used in this product:

All graphical symbols used in this product are from one or more of the following standards:

EN61010-1, IEC417, and ISO3864.

Explosion Hazard!

Harmful (to Health)!

Electrostatic discharge (ESD)

Toxic!

Heavy Instrument!

Disconnect from Mains!

Instruction Manual

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X-STREAM

Emerson Process Management GmbH & Co. OHG S-3

Safety Instructions

Operating and Maintaining this Apparatus

This instrument has left the factory in com-

pliance with all applicable safety regulations.

To maintain this operating condition, the user

must strictly follow the instructions and consider

the warnings in this manual or provided on the

instrument.

Before switching on the instrument, verify that

the electrical supply voltage matches the

instrument´s operating voltage as set in the

factory.

Any interruption in the instrument´s ground line,

whether inside or outside the instrument, or

removal or interruption of its ground line

connection, could result in hazardous operating

conditions. Intentionally interrupting the

instrument´s protective ground is strictly prohi-

bited.

Opening cover panels could expose voltage-

carrying components. Connectors may also be

under voltage. The instrument must be

disconnected from all electrical supplies before

attempting any calibrations, maintenance

operations, repairs or component

replacements requiring opening of the

instrument. Any calibrations, maintenance

operations, or repairs that need the instrument

to be opened while connected to electrical

supplies should be subject to qualified

technicians familiar with the hazards involved

only!

Use only fuses of the correct type and current

ratings as replacements. Using repaired fuses

and short circuiting of fuse holders is prohibited.

Observe all applicable regulations when

operating the instrument from an auto-

transformer or variac.

Substances hazardous to health may emerge

from the instrument‘s exhaust.

Please pay attention to the safety of your

operation personnel. Protective measures

must be taken, if required.

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Emerson Process Management GmbH & Co. OHGS-4

Safety Instructions

ELECTRICAL SHOCK HAZARD !

Do not operate without covers secure. Do not open while energized.

Installation requires access to live parts which can cause death or serious

injury.

For safety and proper performace this instrument must be connected to a

properly grounded three-wire source of power.

SAFETY SUMMARY

To avoid loss of life, personal injury and damage to this equipment and on-site property, do

not operate or service this instrument before reading and understanding this instruction

manual and receiving appropriate training. Save these instructions.

AUTHORIZED PERSONNEL

If this equipment is used in a manner not specified in these instructions, protective systems

may be impaired.

INTENDED USE STATEMENT

X-Stream series gas analyzers are intended to be used as analyzers for industrial purposes.

They must not be used in medical, diagnostic or life support applications nor as safety

devices, and no independent agency certifications or approvals are to be implied as

covering such applications!

TOXIC GASES !

This unit’s exhaust may contain toxic gases such as sulfur dioxide.

These gases can cause serious injuries.

Aviod inhalation of the exhaust gases at the exhaust fitting.

Connect exhaust outlet to a safe vent. Check vent line and connections for

leakage.

Keep all fittings tight to avoid leaks. See section 7-2, page 7-2 for leak test

instructions.

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Emerson Process Management GmbH & Co. OHG S-5

Safety Instructions

HIGH TEMPERATURES !

While working with photometers and/or thermostated components inside

the analyzers hot components may be accessible!

HEAVY INSTRUMENTS !

The analyzer variation X-STREAM F, intended to be wall mounted and/or

outdoor installed, weighs up to approx. 26 kg (57 lbs), depending on

included options!

Use two people and/or suitable tools for transportation and lifting these

instruments!

Take care to use anchors and bolts specified to be used for the weight of

the units!

Take care the wall or stand the unit is intended to be installed at is solid and

stable to hold the units!

EXPLOSION HAZARD !

Do not operate nor install these instruments in hazardous areas with-

out additional measures!

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Emerson Process Management GmbH & Co. OHGS-6

Safety Instructions

Take care of the safety instructions applicable for the gases (sample

gases and test gases) and for the gas bottles containing these gases!

EXPLOSION HAZARD !

Supplying explosive gases is not permitted ! (Explosive gases are mixtures

of flammable gases of concentrations between the explosion limits with air

or oxygen).

Supplying flammable gases of concentrations above the lower explosion

limit (LEL) we recommend to utilize one or more of the following measures:

Before opening gas paths they must be purged with ambient air or

neutral gas (N2) to avoid hazards caused by toxic, flammable,

explosive or harmful to health sample gas components!

INJURY HAZARD !

GASES AND GAS CONDITIONING

• Purging the housing with inert gas

• Internal tubing with stainless steel

• Flame arrestors at gas input and output fittings

• Intrinsically safe paramagnetical or thermal conductivity sensors

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Emerson Process Management GmbH & Co. OHG S-7

Safety Instructions

POWER SUPPLY

Verify the mains voltage at site of installation corresponds to the analyzer´s

rated voltage as given on the nameplate label!

Verify the safety instruction given by power supply unit manufacturer !

Installation and connecting mains and signal cables are subject to qualified

personnel only taking into account all applicable standards and legislative

requirements!

Failure to follow may cause warranty invalidation, property damage and/or

personal injury or death! Connecting mains and signal cables to internal

srew terminals requires working at open housing near life parts!

Installation of this instrument is subject to qualified personnel only, familiar

with the resulting potential risks!

The gas analyzers do not provide a mains power switch and are operable

when connected to power.

The gas analyzers do not provide a mains switch! A mains switch or circuit

breaker (to comply with IEC 60947-1 /-3) has to be provided in the building

installation. This switch has to be installed near by analyzer, must be easily

operator accessible and has to be assigned as disconnector for the analyzer.

Cables for external data processing must be double insulated for mains

voltage when used inside the instrument!

If double insulation is not available signal cables inside the analyzer must

be installed in a way that a distance of at least 5 mm is ensured permanently

(e.g. by utilizing cable ties).

CONNECTING INSTRUMENTS FOR FIXED INSTALLATION

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Emerson Process Management GmbH & Co. OHGS-8

These instruments provide a protective earth terminal. To prevent electrical

shock hazards the instrument must be connected to a protective earth.

Therefore the instrument has to be connected to mains by using a three

wire mains cable with earth conductor!

Any interruption of the earth connector inside or outside the instrument or

disconnecting the earth terminal may cause potential electrical shock

hazzard! Intended interruption of protective earth connections is not

permitted!

ELECTRICAL SHOCK HAZARD !

Safety Instructions

Instruction Manual

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X-STREAM

Emerson Process Management GmbH & Co. OHG S-9

Safety Instructions

General Operating Instructions

DANGER TO LIFE ! EXPLOSION HAZARD !

Verify all gas lines are connected as described within this manual and tight!

Improper gas connections may cause explosion, serious injury or death!

Exhaust may contain hydrocarbons and other toxic gases, e.g. carbon

monoxide. Carbon monoxide is toxic!

• Indoor installation area has to be clean, free from moisture, excessive vibration and frost-

protected.

• Take care to meet the permissible ambient temperatures as given in the technical data section!

Instruments must not be exposed to direct sunlight nor sources of heat. Do not cover venting

openings and take care to mount the instrument in a distance to walls not affecting venting.

• Do not interchange gas inlet and outlet! All gases must be conditioned before supplying! When

supplying corrosive gases ensure that gas path components are not affected!

• Max. permissible gas pressure: 1,500 hPa (7.5 psig), except with paramagnetic Oxygen sensor

(atmospheric pressure;

page 3-17)!

• Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected

and in compliance with applicable legislative requirements!

• When it is necessary to open gas paths seal the analyzer‘s gas fittings by using PVC caps to

avoid pollution of the internal gas path by moisture, dust, etc.

• To stay in compliance with regulations regarding electromagnetic compatibility it is recommended

to use only shielded cables, as optionally available from Emerson Process Management or

equivalent. Customer has to take care that the shield is connected in proper way ( section

4-5, page 4-29). Shield and signal connector enclosure need to be conductively connected,

submin-d plugs and sockets must be screwed to the analyzer.

• Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic

compatibility. In this case the customer has to take measures to stay in compliance and has to

declare conformity, when required by legislation (e.g. European EMC Directive).

General Operating Instructions

X-STREAM

Instruction Manual

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Emerson Process Management GmbH & Co. OHGS-10

Magnetically Operated Front Panel

DANGER TO LIFE !

Persons with cardiac pacemakers should absolutely avoid magnetic

fields !

Negative effects on persons beyond those described above caused by

magnetic fields are not known. It is presumed that persons showing allergic

reaction on contact with ceramic or metallic material show the same

behavior on contact with magnetic material.

Permanent magnets are surrounded by magnetic fields. These magnetic

fields can disturb and even destroy sensitive electronic measuring devices,

but also mechanical watches, credit cards, etc.

Usually a distance of 20 inch (0.5 m) is enough to avoid damages. All sintered

permanent magnets are hard and brittle. Hitting of sintered permanent

magnets by the magnetic attraction causes splitting into fragments with many

sharp edges. This especially occurs with high energy magnets, and can

also cause skin bruises by high attraction.

High energy magnets made of rare-earth materials have to be stored dry,

otherwise the surfaces would oxidise. Unprotected operation in a humid

environment may cause corrosion. Avoid damaging the protective galvanic

coating.

A storage in a hydrogen atmosphere destroys these magnets. A

demagnetisation is caused when permanent magnet materials have been

exposed in a radioactive radiation for a long time.

For air transportation of magnetic material the IATA instructions have to be

observed:

Magnetic fields are not allowed to penetrate the package, if necessary the

magnets have to be shorted using a metal plate.

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Instruction Manual

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Emerson Process ManagementGmbH & Co. OHG

Table of Contents

SHORT FORM GUIDE FOR THIS MANUAL

To find information about see chapter

Safety measures ................................................ S

The different instruments designs .................. 1

The instruments technical data ....................... 2

Measuring principles characteristics............. 3

How to install the instruments.......................... 4

Software menu structure, how to navigate

and menu entries descriptions........................ 5

1

st

startup procedures,

checking the instrument‘s setup..................... 6

Basic procedures .............................................. 7

Maintenance procedures ................................. 7

Status messages and troubleshooting .......... 8

Modbus Parameters.......................................... 9

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TABLE OF CONTENTS

Preamble S-1

Definitions S-1

Safety Instructions S-2

General Operating Instructions ............................................................................................ S-9

Magnetically Operated Front Panel.................................................................................... S-10

Chapter 1 Technical Description 1-1

1-1 Overview .....................................................................................................................1-1

1-2 X-STREAM General Purpose Tabletop or Rack Mount Version ............................1-4

1-3 X-STREAM F (Field Housing).................................................................................... 1-6

1-4 Reserved For Future Use ........................................................................................ 1-11

1-5 Gaspath Design........................................................................................................1-12

1-5-1 Gas Paths Materials .............................................................................................1-12

1-5-2 Safety Filter...........................................................................................................1-12

1-5-3 Fittings ..................................................................................................................1-12

1-5-4 Piping....................................................................................................................1-12

1-5-5 Gas Path Variations .............................................................................................1-13

1-6 Optional Gas Path Components.............................................................................1-15

1-6-1 Internal Sample Gas Pump .................................................................................1-15

1-6-2 Internal Valve Block .............................................................................................1-15

1-6-3 Internal Flow Monitor...........................................................................................1-15

1-6-4 Internal Barometric Pressure Sensor ................................................................1-15

1-6-5 Optional Heated Compartment...........................................................................1-16

1-7 Interfaces ..................................................................................................................1-17

1-7-1 Analog Outputs ....................................................................................................1-17

1-7-2 Modbus Interface .................................................................................................1-17

1-7-3 Status Signals (NAMUR) .....................................................................................1-17

1-8 Optional Interfaces...................................................................................................1-18

1-8-1 Digital Outputs .....................................................................................................1-18

1-8-2 Digital Inputs ........................................................................................................1-18

1-8-2-1 Remotely Activating a Calibration Procedure using IN 1 to IN 3.................1-19

1-8-2-2 Valve Control....................................................................................................1-20

1-8-2-3 Remote Pump Control ....................................................................................1-20

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Table of Contents

Chapter 2 Technical Data 2-1

2-1 Common Technical Data ........................................................................................... 2-2

2-2 Model Specific Technical Data..................................................................................2-5

2-2-1 X-STREAM GP, GPS Tabletop or Rack Mount Version.......................................2-5

2-2-1-1 Terminals Version..............................................................................................2-6

2-2-1-2 Sockets Version.................................................................................................2-8

2-2-2 X-STREAM F Field Housing................................................................................2-10

2-3 Information on the Nameplate Label ......................................................................2-13

Chapter 3 Measuring Principles 3-1

3-1 Infrared Measurement (IR), Ultraviolet Measurement (UV).....................................3-1

3-1-1 Interference Filter Correlation (IFC) .....................................................................3-1

3-1-2 Opto Pneumatic Measuring Principle ..................................................................3-3

3-1-3 Technical Implementation.....................................................................................3-4

3-2 Oxygen Measurement................................................................................................3-9

3-2-1 Paramagnetic Measurement................................................................................. 3-9

3-2-2 Electrochemical Measurement ........................................................................... 3-11

3-2-3 Special Hints on Oxygen Sensors .....................................................................3-13

3-3 Thermal Conductivity Measurement ......................................................................3-14

3-3-1 Principle of Operation..........................................................................................3-14

3-3-2 Technical Implementation...................................................................................3-15

3-4 Measurement Specification ....................................................................................3-16

Chapter 4 Installation 4-1

4-1 Abstract.......................................................................................................................4-1

4-2 Gas Conditioning .......................................................................................................4-2

4-3 Electrical Connections ..............................................................................................4-5

4-4 Detailled Installation Instructions .............................................................................4-6

4-4-1 X-STREAM GP, X-STREAM GPS...........................................................................4-6

4-4-1-1 Plugs & Sockets Version ..................................................................................4-7

4-4-1-2 Terminals Version............................................................................................4-13

4-4-2 X-STREAM F.........................................................................................................4-20

4-5 Hints on Wiring Signal Inputs and Outputs...........................................................4-29

4-5-1 Electrical Connections in General......................................................................4-29

4-5-2 Wiring Inductive Loads .......................................................................................4-31

4-5-3 Driving Multiple Loads ........................................................................................4-31

4-5-4 Driving High Current Loads................................................................................4-32

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Emerson Process Management GmbH & Co. OHG

Chapter 5 User Interface and Software Menus 5-1

5-1 Abstract.......................................................................................................................5-1

5-2 The User Interface...................................................................................................... 5-1

5-2-2 The Status LEDs .................................................................................................... 5-2

5-2-1 The Display............................................................................................................. 5-2

5-2-3 The Keys................................................................................................................. 5-3

5-2-3-1 Magnetically Operated Front Panel .................................................................5-4

5-3 Software...................................................................................................................... 5-5

5-3-1 Power-On Sequence .............................................................................................5-5

5-3-2 Measuring Screen.................................................................................................. 5-5

5-3-3 Menu Structure ......................................................................................................5-6

5-3-4 Navigating and Editing..........................................................................................5-6

5-3-5 Access Levels ........................................................................................................ 5-8

5-3-6 Special Screens .....................................................................................................5-9

5-4 Menu System ............................................................................................................5-10

5-4-1 Power-On and Measuring Screen ...................................................................... 5-11

5-4-2 Control Menu........................................................................................................5-13

5-4-2-1 Zero Calibration Menu.....................................................................................5-14

5-4-2-2 Span Calibration Menu ...................................................................................5-15

5-4-2-3 Advanced Calibration Menu ...........................................................................5-16

5-4-2-4 Calibration Status Screen...............................................................................5-17

5-4-2-5 Apply Gas Menu...............................................................................................5-18

5-4-2-6 Acknowledgements Menu ..............................................................................5-19

5-4-3 Setup Menu ..........................................................................................................5-20

5-4-3-1 Display Setup Menu ........................................................................................5-21

5-4-3-1-1 Display Language Setup Menu .................................................................5-23

5-4-3-1-2 Menu Access Setup Menu..........................................................................5-24

5-4-3-1-3 Component Setup Menu ............................................................................5-25

5-4-3-2 Calibration Setup Menu ..................................................................................5-26

5-4-3-2-1 Calibration Gases Setup Menu ..................................................................5-27

5-4-3-2-2 Interval Time Setup Menu...........................................................................5-28

5-4-3-3 Measurement Setup Menu..............................................................................5-29

5-4-3-3-1 Signal Damping Setup Menu .....................................................................5-30

5-4-3-3-2 Cross Interference Setup Menu.................................................................5-31

5-4-3-3-3 AD Conversion Setup Menu ......................................................................5-32

5-4-3-4 In/Outputs Setup Menu ...................................................................................5-33

5-4-3-4-1 Analog Output Setup Menu........................................................................5-34

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Table of Contents

5-4-3-4-1-1 Analog Output Signal Setup ..................................................................5-35

5-4-3-4-1-2 Analog Output Range Setup..................................................................5-36

5-4-3-4-1-3 Analog Output Signal Scaling Setup ....................................................5-38

5-4-3-4-1-4 Analog Output Signal Trimming ............................................................5-39

5-4-3-4-2 Valve Assignment........................................................................................5-40

5-4-3-5 Installed Options Setup Menu ........................................................................5-41

5-4-3-6 Communication Setup Menu..........................................................................5-42

5-4-3-7 Alarms Setup Menu .........................................................................................5-43

5-4-3-8 Save-Load Menu..............................................................................................5-44

5-4-3-9 Miscellaneous Screen.....................................................................................5-46

5-4-4 Status Menu .........................................................................................................5-47

5-4-4-1 Failure Status Screen......................................................................................5-48

5-4-4-2 Check Requests Status Screen.....................................................................5-49

5-4-4-3 Function Check Status Screen ......................................................................5-50

5-4-4-4 Off Spec Status Screen...................................................................................5-51

5-4-4-5 Calibration Status Screen...............................................................................5-52

5-4-4-6 Measurement Status Screen ..........................................................................5-53

5-4-4-7 Alarms Status Screen .....................................................................................5-54

5-4-5 Info Menu ..............................................................................................................5-55

5-4-5-1 Measuring Range Info Screen........................................................................5-56

5-4-5-2 Factory Settings Screen .................................................................................5-57

5-4-5-3 Installed Options Info Screen .........................................................................5-58

Chapter 6 Initial Startup 6-1

6-1 Abstract.......................................................................................................................6-1

6-2 Checking the Instrument's Setup.............................................................................6-2

6-2-1 Instrument's Language Setup..............................................................................6-3

6-2-2 Display Information Setup ....................................................................................6-4

6-2-3 Calibration Data Setup ..........................................................................................6-4

6-2-4 Analog Output Setup.............................................................................................6-7

6-2-5 Concentration Alarms Setup ..............................................................................6-12

Chapter 7 Maintenance 7-1

7-1 Abstract.......................................................................................................................7-1

7-2 Performing a Leak Test..............................................................................................7-2

Table of Contents

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7-3 Calibration Procedures ............................................................................................ 7-3

7-3-1 Preparing a Calibration .........................................................................................7-4

7-3-2 Manual Calibration................................................................................................. 7-7

7-3-2-1 Manual Zero Calibration.................................................................................... 7-7

7-3-2-2 Manual Span Calibration ..................................................................................7-8

7-3-3 Advanced Calibration..........................................................................................7-10

7-3-3-1 Additional Preparations for Advanced Calibration ...................................... 7-11

7-3-3-2 Zero All Calibration ..........................................................................................7-14

7-3-3-3 Span All Calibration .........................................................................................7-16

7-3-3-4 Zero & Span All Calibration.............................................................................7-18

7-3-4 Auto Calibration ...................................................................................................7-21

7-3-4-1 Additional Preparations for Auto Calibration................................................7-21

7-3-4-2 Zero Auto Calibration ......................................................................................7-24

7-3-4-3 Span Auto Calibration .....................................................................................7-26

7-3-4-4 Unattended Auto Calibration..........................................................................7-28

7-3-5 Resetting a Calibration........................................................................................7-30

7-3-6 Verifying a Calibration .........................................................................................7-30

7-3-7 Cancelling an Ongoing Calibration....................................................................7-31

7-3-8 Cross Interference Compensation.....................................................................7-33

7-4 Replacing the ElectrochemicalSensor .................................................................7-35

7-4-1 Precautions for Sensor Handling ......................................................................7-37

7-4-2 Opening the Analyzer ..........................................................................................7-38

7-4-2-1 Opening X-STREAM GP / GPS .......................................................................7-39

7-4-2-2 Opening X-STREAM F.....................................................................................7-39

7-4-3 Locating the Sensor ...........................................................................................7-40

7-4-4 Sensor Unit Disassembly ...................................................................................7-41

7-4-5 Sensor Amplifier Adjustment ..............................................................................7-42

7-4-6 Finalizing the Sensor Replacement...................................................................7-43

7-5 Cleaning the Instrument's Outside.........................................................................7-44

7-6 Save / Restore Configuration Data Sets ................................................................7-45

7-6-1 Save CfgData to UserData ..................................................................................7-46

7-6-2 Restore UserData to CfgData .............................................................................7-47

7-6-3 Restore FactData to CfgData..............................................................................7-48

7-6-4 Save / Restore to an External Device.................................................................7-49

7-6-4-1 Save CfgData to COMPort ..............................................................................7-50

7-6-4-2 Restore COMPort to CfgData .........................................................................7-52

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Table of Contents

Chapter 8 Troubleshooting 8-1

8-1 Abstract.......................................................................................................................8-1

8-2 Solving Problems Indicated by Status Messages .................................................. 8-2

8-3 Solving Problems Not Indicated by Status Messages ...........................................8-8

8-4 Troubleshooting on Components..........................................................................8-12

8-4-1 Opening X-STREAM GP / GPS............................................................................8-12

8-4-2 Opening X-STREAM F .........................................................................................8-12

8-4-3 Measuring Points.................................................................................................8-13

8-4-3-1 Measuring Points at BKS Board ....................................................................8-13

8-4-3-1-1 Supply voltage +6 V ....................................................................................8-13

8-4-3-1-2 Positive reference voltage..........................................................................8-13

8-4-3-1-3 Negative reference voltage.............................................................................8-15

8-4-3-1-4 Temperature sensor....................................................................................8-15

8-4-3-1-5 Light barrier signal ......................................................................................8-15

8-4-3-1-6 Analog Preamplifier.....................................................................................8-16

8-4-3-2 Measuring Points at OXS Board (Electrochemical Oxygen Measurement)8-17

8-4-3-2-1 Sensor Signal ..............................................................................................8-17

8-4-4 BKS 20 Board Jumper Configuration................................................................8-18

8-4-5 Fuse on BKS 20 Board .......................................................................................8-19

Chapter 9 Modbus Functions 9-1

9-1 Abstract.......................................................................................................................9-1

9-2 Supported Functions ................................................................................................ 9-2

9-3 List of Parameters and Registers .............................................................................9-2

9-4 Comparison of Registers and Parameters ............................................................9-17

Chapter 10 Service Information 10-1

10-1 Return of Material.....................................................................................................10-1

10-2 Customer Service ....................................................................................................10-2

10-3 Training .....................................................................................................................10-2

Appendix A-1

A-1 Modbus Implementation........................................................................................... A-2

A-2 EC Declaration of Conformity................................................................................ A-12

A-3 Block Diagrams....................................................................................................... A-13

Table of Contents

T-8

X-STREAM

Instruction Manual

HASAxE-IM-HS

05/2006

Emerson Process Management GmbH & Co. OHG

Index of Figures

Fig. 1-1: X-STREAM GP, GPS, front side view......................................................................................................1-4

Fig. 1-2: X-STREAM GP, terminals version, rear side view .................................................................................1-5

Fig. 1-3: X-STREAM GPS, plugs and sockets version, rear side view................................................................1-5

Fig. 1-4: X-STREAM F, front side view & rear side view at carrying handle ......................................................1-7

Fig. 1-5: X-STREAM F, front panel ........................................................................................................................1-8

Fig. 1-6: X-STREAM F, bottom view .....................................................................................................................1-9

Fig. 1-7: X-STREAM F, mains and signal terminals (front door removed) .......................................................1-10

Fig. 1-8: Single channel or serial tubing ............................................................................................................1-13

Fig. 1-9: Dual channel parallel tubing.................................................................................................................1-12

Fig. 1-10: Single channel or serial tubing, with options ...................................................................................1-14

Fig. 1-11: Dual channel parallel tubing, with options ........................................................................................1-15

Fig. 1-12: Optional Heated Compartment ...........................................................................................................1-16

Fig. 1-13: Digital Outputs - Schematic ................................................................................................................1-18

Fig. 1-14: Digital Inputs - Priorities ......................................................................................................................1-19

Fig. 2-1: X-STREAM GP, GPS - dimensions [approx. mm (inch)] .......................................................................2-5

Fig. 2-2: X-STREAM GP, (terminals version) - terminals and fuse holders ........................................................2-7

Fig. 2-3: X-STREAM GPS, (sockets version) - power and signals connectors ..................................................2-8

Fig. 2-4: X-STREAM F - dimensions (approx. mm [inch]) .................................................................................2-10

Fig. 2-5: X-STREAM F - mains terminals / fuse holders ....................................................................................2-11

Fig. 2-6: X-STREAM F - signals terminals ..........................................................................................................2-12

Fig. 2-7: Analyzer Nameplate Label (example)...................................................................................................2-13

Fig. 3-1: Absorption Bands of Measured Gases and Transmission of Interference Filters ................................3-2

Fig. 3-2: Gas Detector Design Principle ................................................................................................................3-3

Fig. 3-3: IR Photometer Assembly Principle .........................................................................................................3-5

Fig. 3-4: Photometer Assembly with Pyroelectrical Detector ..............................................................................3-7

Fig. 3-5: IR & UV Photometer Assemblies with Gas Detectors .............................................................................3-8

Fig. 3-6: Paramagnetic Oxygen Detector, Assembly Principle ..........................................................................3-10

Fig. 3-7: Electrochemical Sensor - Assembly Principle..................................................................................... 3-11

Fig. 3-8: Electrochemical reaction of Oxygen Sensor .......................................................................................3-12

Fig. 3-9: Wheatstone Bridge ................................................................................................................................3-15

Fig. 3-10a: TC cell, exterior view .........................................................................................................................3-15

Fig. 3-10b: TC cell - sectional view......................................................................................................................3-15

Fig. 4-0: Example of gas fittings label...................................................................................................................4-3

Fig. 4-1: Bypass Mode Installation.........................................................................................................................4-5

Fig. 4-2:Frontal view...............................................................................................................................................4-6

Fig. 4-3: Rear panel - plugs & sockets version .....................................................................................................4-7

Fig. 4-4: Socket X1 - pin assignment ....................................................................................................................4-8

Fig. 4-5: Socket X2 - pin assignment ....................................................................................................................4-9

Fig. 4-7: Plug X3 - pin assignment ......................................................................................................................4-10

Fig. 4-6: Relay status signals, block diagram .....................................................................................................4-10

Fig. 4-8: Socket X4 - pin assignment ..................................................................................................................4-11

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